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Cutting Clearance

Cutting clearance is the gap between the punch and die during sheet metal cutting. The optimal clearance results in a small edge radius and burnished cut band, maximizing tool life and part quality. Excessive clearance causes larger edge radii and burrs, while insufficient clearance leads to wider cut bands or multiple bands and fractures starting at the clearance rather than cut edges. Proper clearance is calculated based on sheet thickness and material properties to balance part quality and tool life.

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215 views2 pages

Cutting Clearance

Cutting clearance is the gap between the punch and die during sheet metal cutting. The optimal clearance results in a small edge radius and burnished cut band, maximizing tool life and part quality. Excessive clearance causes larger edge radii and burrs, while insufficient clearance leads to wider cut bands or multiple bands and fractures starting at the clearance rather than cut edges. Proper clearance is calculated based on sheet thickness and material properties to balance part quality and tool life.

Uploaded by

vinod
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CUTTING CLEARANCE

Cutting Clearance:Cutting clearance is the gap between a side of the punch and the
corresponding side of the die opening when the punch is entered into the die opening.
Cutting clearnace should always be expressed as the amount of clearance per side.
Proper cutting clearance is necessary for the longer life of the tool.Quality of the piece
part also depends on proper cutting clearance.A visual examination of the punched
components will indicate the amount of clearnace and whether the punch and die have
- optimum cutting clearance or
- excessive clearance or
- misalignment
Optimum Cutting Clearance:
When optimum cutting clearance condition exists a small edge radius is formed.
The edge radius is the result of the plastic deformation (first stage of shearing).A
highly burnished cut band is approximately one third the thickness of the stock
material.The balance of the cut is the break resulting from fracture(third
Stage).Excessive cutting clearance:the gap between the punch and the die is
comparatively more in this case.The stock material reacts to the initial pressure on a
manner approaching that of forming rather than cutting.Therefore the edge radius
becomes larger.It does not blend smoothly with the cut band.The cut band becomes
smaller.The break shows greater irregularities.
Heavy burrs are noticeable all along the cut contour.The burr results from the
dragging of the material.Insufficient cutting clearance:When cutting clearance is
slightly less,the width of the cut band will be more.If cutting clearance is too less two
or more cut bands will be formed.Because of the steeper angle between the punch and
the die cut edges the resistance of the stock material to fracture is increased.The
resulting pressure will cause the initial fracture to originate at clearance rather than at
the cut edges.Burr may be caused by compressive forces. Misalignment between
punch and DieThe cutting characteristics also indicate whether the punch and die
openings are in accurate alignment.Because of misalignment,clearance on one side
increases and the other side decreases.The component will show the corresponding
difference on cut band.
Burr side
The burr side is adjacent to the break.Burr should be practically nonexistent
- if the cutting clearance between the punch and die is optimum.
- if the cutting edges are sharp.
The burr side of a blank or slug is always towards the punch(die stars shearing)The
burr side of a punched opening is always towards the die opening (punch starts
shearing).The characterstics of the blank or slug and the punched opening are
inversely idential.
Relationship of piece part size to punch and die size
when pierced or blanked piece parts are measured,the measurement is made at the cut
band.
Blanking
The actual cutting of the blank or slug is done by the cutting edge of the die opening
.Therefore the die opening determines the size of the blank or slug.
BLANKING PUNCH SIZE=BLANK SIZE-TOTAL CLEARANCE
BLANKING DIE SIZE=BLANK SIZE
Piercing
The actual cutting of the opening in the stock material is done by punch.Therefore the
size of a punched opening is determined by the punch.
PIERCING PUNCH SIZE=PIERCED HOLE SIZE
PIERCING DIE SIZE=PIERCED HOLE SIZE+TOTAL CLEARANCE
Clearance calculation:
The ideal clearance can be caluculated by the following formula
Clearance=C*s*square root of (T max/10)
where C is a constant=0.005 for very accurate component
=0.01 for normal components
s=sheet thickness in mm
T max=shear strength of the stock material in N/mm square
T max for some materials:
St.steel=400N/mm square
MS=400N/mm square
Brass=200N/mm srqare
aluminium=100N/mm square
Copper=250N/mm square

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